Browse Topic: Braking systems
This SAE Standard applies to machines as defined in Appendix A. Some of these machines can travel on-highway but function primarily off-highway.
As the adoption of electric vehicles continues to accelerate, the demand for their development and testing using chassis dynamometers has also increased significantly. Compared with internal combustion engine vehicles, chassis dynamometer testing for electric vehicles typically requires test durations several to several dozen times longer, resulting in substantially increased labor requirements. In addition, low-temperature testing is often required, further intensifying the workload associated with vehicle testing. To address these challenges, this study developed and evaluated a pedal robot designed to enable unmanned and automated testing. The pedal robot developed in this study weighs only 12 kg and can be installed within a few minutes. It is, to the authors’ knowledge, the world’s first pedal robot that mimics human driving behavior by using a single foot to operate both the accelerator and brake pedals. Unlike conventional driving robots, the actuators of the proposed system do
With the growing trend of electric vehicles (EVs) incorporating regenerative braking systems, many compact SUVs, including hybrids and EVs, still utilize drum brakes on the rear wheels to strike a balance between cost, performance, and durability. Drum brake squeal remains a complex and persistent challenge in the field of vehicle noise, vibration, and harshness (NVH). This issue stems from dynamic instability caused by time–dependent friction forces. Traditional linear modal analysis has been used to study the mechanisms behind drum brake squeal, focusing on harmonic vibrations in large–scale models. However, these methods often fail to accurately correlate with real world behavior due to the presence of extra, non-physical modes. To address this, time–domain analysis approaches have been explored, incorporating detailed friction models and contact mechanics. These methods consider different root causes for high and low–frequency squeal and have shown promising results in accurately
The purpose of this SAE Recommended Practice is to establish a uniform laboratory procedure for securing and reporting the friction and wear characteristics of brake linings. The performance data obtained can be used for in-plant quality control by brake lining manufacturers and for the quality assessment of incoming shipments by the purchasers of brake linings.
This SAE Recommended Practice covers equipment capabilities and the test procedure to quantify and qualify the shear strength between the friction material and backing plate or brake shoe for automotive applications. This SAE Recommended Practice is applicable to: bonded drum brake linings; integrally molded disc brake pads; disc brake pads and backing plate assemblies using mechanical retention systems (MRS); coupons from drum brake shoes or disc brake pad assemblies. The test and its results are also useful for short, semi-quantitative verification of the bonding and molding process. This Recommended Practice is applicable during product and process development, product verification and quality control. This Recommended Practice does not replicate or predict actual vehicle performance or part durability.
This document is written to address acceleration and deceleration control issues related to heavy-duty trucks and buses greater than 10000 GVW.
This SAE Recommended Practice provides procedures and methods for testing service, spring applied parking, and combination brake actuators with respect to durability, function, and environmental performance. A minimum of six test units designated A, B, C, D, E, and F are to be used to perform all tests per 1.1 and 1.2.
This SAE Recommended Practice provides a common method to measure wear of friction materials (brake pad assemblies and brake shoes) and their mating parts (brake disc or brake drum). These wear measurements apply to brakes fitted on passenger cars and light trucks up to 4536 kg of Gross Vehicle Weight Rating under the Federal Motor Vehicle Safety Standard (FMVSS), or vehicles category M1 (passenger cars up to nine occupants, including the driver) under the European Community’s ECE Regulations.
The SAE J2923 procedure is a recommended practice that applies to on-road vehicles with a GVWR below 4540 kg equipped with disc brakes.
Indian passenger car accident data indicates that approximately 44% of crashes are frontal impacts (Refer fig 1). Among the injuries sustained in these crashes, lower leg injuries are notably critical, contributing to nearly 25% of driver occupant injuries (Refer fig 2). To evaluate such injuries, the Bharat New Car Assessment Program (BNCAP) includes lower leg injury metrics as part of the Frontal Offset Deformable Barrier (ODB64) test. While the overall injury performance is assessed at the vehicle level, BNCAP also monitors vehicle interior intrusions—particularly pedal intrusions—as key contributors to lower limb injury severity. A major challenge in frontal crashes is the intrusion of the vehicle's front-end structure into the occupant compartment. Rigid components, particularly the brake pedal assembly, can be displaced rearward during a crash, significantly increasing the risk of lower leg injuries. Therefore, minimizing pedal intrusions into the driver foot-well is critical for
The objective of this paper is to evaluate the thermal performance of the brake discs in the design stage of its life cycle by developing a methodology to replicate dynamometer testing using multi-disciplinary Finite Element Analysis (FEA) methods. A simulation workflow was formulated in which Computational Fluid Dynamics (CFD) was used to create temperature and velocity dependent Heat Transfer Coefficients (HTC) which were in turn used in Computer Aided Engineering (CAE) to do a thermo-mechanical analysis. With this workflow various designs of the brake discs were analyzed. A sensitivity study was done to determine critical design features that affected its thermal performance. A final design was fixed that met both the weight and thermal performance targets. This design was evaluated in dynamometer testing, and 93% correlation was achieved. Thus, the developed simulation workflow ensured that a first-time right brake disc can be finalized in the design stage, which will meet the
This study presents an integrated vehicle dynamics framework combining a 12-degree-of-freedom full vehicle model with advanced control strategies to enhance both ride comfort and handling stability. Unlike simplified models, it incorporates linear and nonlinear tire characteristics to simulate real-world dynamic behavior with higher accuracy. An active roll control system using rear suspension actuators is developed to mitigate excessive body roll and yaw instability during cornering and maneuvers. A co-simulation environment is established by coupling MATLAB/Simulink-based control algorithms with high-fidelity multibody dynamics modeled in ADAMS Car, enabling precise, real-time interaction between control logic and vehicle response. The model is calibrated and validated against data from an instrumented test vehicle, ensuring practical relevance. Simulation results show significant reductions in roll angle, yaw rate deviation, and lateral acceleration, highlighting the effectiveness
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